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How #Toyota evaluates physical burden of work positions using TVAL (#Lean)

April 11th, 2012 Posted in Lean Tags: , ,

I think you will spend 67 seconds reading this post

I just came across the following paper describing how Toyota analyzes each and every job for physical hard and dangerous work condition. I wish more plants would use such a work condition measurement tool.

Strategy for Health and Safety Management at an Automobile Company
– From the Prevention of Low Back Pain to Toyota’s Verification of Assembly Line (TVAL)

Now, I’m in the Service Industry. How could that be done similarly? Burden would have to be seen from the point of view of a worker’s mind perspective.

Just taking into consideration the formula Weight burden index (B)=sum(WxNxL)xT/1000 could yield something like:

  • Weight = difficulty of work: from simple mental calculus to highly mental computation & decision making…
  • Number = number of times per job the “heavy” work has to be done
  • L = Movement coefficient = an index of where that work occurs, of the conditions: under time constraints (eg. harder at the end of the process with a deadline than at the beginning)? Is it well defined (existing standard)? Is it always changing? Does it requires deep thinking before working? Risks of errors? Does it fit into a bigger picture (part of a bigger process)?
  • Time coefficient = duration of difficult task

Of course, evaluation the TVAL of a work has no point if it’s not for its improvement…

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